Fred Dryer was originally slated to play Sam Malone before Ted Danson was chosen. The early version of Sam was envisioned as a retired football player, fitting Dryer’s background as a former professional football defensive end.
Danson ultimately won the role partly because he was younger and had more acting experience. After Danson’s casting, the character was changed from a former football player to Sam “Mayday” Malone, a retired baseball relief pitcher. That adjustment made Danson’s physical type and screen persona fit the character more naturally.
The casting history is sometimes muddled because several well-known actors were considered. William Devane and Fred Dryer were tested in Sam-and-Diane pairings, while Bill Cosby was also considered early in the process. Tom Skerritt is another name sometimes associated with the role, but Dryer is the canonical answer to the question about who was originally slated to play Sam.